CN109318485B

CN109318485B - System and method for controlling an additive manufacturing system

Info

Publication number: CN109318485B
Application number: CN201810842642.4A
Authority: CN
Inventors: J·J·玛德隆; T·C·爱德考克; 小贾斯汀·J·甘博内; M·E·格拉哈姆; S·罗伊乔杜里; D·J·厄诺
Original assignee: General Electric Co
Current assignee: General Electric Co
Priority date: 2017-07-31
Filing date: 2018-07-27
Publication date: 2021-05-28
Anticipated expiration: 2038-07-27
Also published as: EP3437763A2; CN109318485A; JP2019043130A; US20190033828A1; US10514680B2; JP6835777B2; EP3437763A3

Abstract

The invention provides a method of manufacturing a component using an additive manufacturing system. The method includes providing a build file on a controller of an additive manufacturing system. The build file includes at least one generating function, at least one seed value, and at least one function parameter. The method also includes generating a curve corresponding to the component based on the at least one generating function, the at least one seed value, and the at least one function parameter. The method also includes positioning a material on the surface. The method also includes determining, using the controller, a plurality of set points for the consolidation apparatus. The plurality of set points are positioned along the curve. The method also includes operating a consolidation device of the additive manufacturing system to consolidate a material. The invention also provides an additive manufacturing system for manufacturing a part using the build document.

Description

System and method for controlling an additive manufacturing system

Technical Field

The field of the present application relates generally to additive manufacturing systems and, more particularly, to systems and methods for manufacturing three-dimensional parts using build files that include at least one function.

Background

A three-dimensional part is manufactured using an additive manufacturing system and process. For example, in some additive manufacturing processes, successive layers of material are solidified layer-by-layer to manufacture a component. At least some known additive manufacturing systems use a laser (or similar energy source) and a series of lenses and mirrors to direct the laser over the powdered material. Some known additive manufacturing systems include Direct Metal Laser Melting (DMLM), Selective Laser Sintering (SLS), Direct Metal Laser Sintering (DMLS), Selective Laser Melting (SLM), and laser melting (LaserCusing) systems.

Some known additive manufacturing systems include a controller that receives an electronic file and directs a laser using the electronic file. In some known additive manufacturing systems, the electronic file includes coordinate data, such as vectors, describing a series of linear segments to approximate portions of the three-dimensional part. However, complex three-dimensional components require multiple linear sections to approximate portions of the component. As the file size is increased to accommodate multiple linear sections, the time required for the controller to receive and process the electronic file also increases. As a result, the cost of producing the three-dimensional part increases. Furthermore, electronic files limit the accuracy with which an additive manufacturing system can produce three-dimensional parts.

Disclosure of Invention

In one aspect, a method of manufacturing a component using an additive manufacturing system is provided. The method includes providing a build file on a controller of an additive manufacturing system. The build file includes at least one generating function, at least one seed value, and at least one function parameter. The method also includes generating a curve corresponding to the component based on the at least one generating function, the at least one seed value, and the at least one function parameter. The method also includes positioning a material on the surface. The method also includes determining, using the controller, a plurality of set points for the consolidation apparatus. The plurality of set points are positioned along the curve. The method also includes operating a consolidation device of the additive manufacturing system to consolidate a material.

In another aspect, an additive manufacturing system for manufacturing a component using a build file is provided. The additive manufacturing system includes a controller configured to receive a build file. The build file includes at least one generating function, at least one seed value, and at least one function parameter. The additive manufacturing system also includes a positioning device configured to position a material on a surface. The additive manufacturing system also includes a consolidation device connected to the controller and positionable relative to the surface. The consolidation apparatus is configured to consolidate a material. The controller is configured to determine a plurality of set points for the consolidation apparatus along a curve defined by the at least one generating function, the at least one seed value, and the at least one function parameter.

Technical solution 1. a method of manufacturing a component using an additive manufacturing system, the method comprising: providing a build file on a controller of an additive manufacturing system, wherein the build file comprises at least one generation function, at least one seed value, and at least one function parameter; generating a curve corresponding to the component based on the at least one generating function, the at least one seed value, and the at least one function parameter; positioning a material on a surface; determining, using the controller, a plurality of set points for a consolidation apparatus of the additive manufacturing system, wherein the plurality of set points are positioned along the curve; and operating the consolidation apparatus to consolidate the material.

Solution 2. the method of solution 1 wherein the plurality of set points determined by the controller are located along a non-linear portion of the curve.

Technical solution 3 the method of claim 1, wherein providing a build file on a controller of the additive manufacturing system comprises providing program code comprising the at least one generating function, wherein at least a portion of the program code is customized for the component.

Technical solution 4. the method according to technical solution 1, further comprising selecting the at least one generating function from a database.

Solution 5. the method of solution 1, wherein the at least one generating function defines at least one of a B-spline curve, a hilbert curve, a lattice, and a unit cell unit.

Solution 6. the method of solution 1, further comprising determining an actual position of the consolidation apparatus and comparing the actual position to the plurality of set points.

Claim 7. the method of claim 1, further comprising transmitting a build file for the component to the controller.

The method of claim 8, wherein the at least one generating function includes a first generating function associated with a first portion of the component and a second generating function associated with a second portion of the component.

Claim 9 the method of claim 8, wherein the first layer of the component is formed using the first generating function and the second layer of the component is formed using the second generating function.

Solution 10. the method of solution 1, further comprising providing at least one user input to the at least one generating function, wherein the generating function is executable to define the curve based on the at least one user input.

Technical solution 11 the method of claim 1, wherein the at least one generating function is encrypted, the method further comprising reading a key of the build file to decrypt the generating function.

Solution 12. an additive manufacturing system for manufacturing a part using a build document, the additive manufacturing system comprising: a controller configured to receive a build file, wherein the build file comprises at least one generation function, at least one seed value, and at least one function parameter; a positioning device configured to position a material on a surface; and a consolidation device connected to the controller and positionable relative to the surface, wherein the consolidation device is configured to consolidate material, wherein the controller is configured to determine a plurality of set points for the consolidation device along a curve defined by the at least one generating function, the at least one seed value, and the at least one function parameter.

Solution 13. the additive manufacturing system of solution 12, wherein the plurality of set points determined by the controller are located along a non-linear portion of the curve.

Technical solution 14 the additive manufacturing system according to claim 12, wherein the build file includes program code including the at least one generating function, wherein at least a portion of the program code is customized for the part.

Solution 15 the additive manufacturing system according to solution 12, further comprising a database comprising a plurality of generating functions, wherein the at least one generating function of the build file is selected from the generating functions in the database.

Solution 16. the additive manufacturing system of solution 12, wherein the at least one generating function defines at least one of a B-spline curve, a hilbert curve, a lattice, and a unit cell unit.

Solution 17 the additive manufacturing system of solution 12, further comprising an imaging device configured to provide an image for determining a true position of the consolidation device, wherein the controller is configured to compare the true position to the plurality of set points.

Solution 18. the additive manufacturing system of solution 12, wherein the at least one generating function comprises a first generating function relating to a first portion of the component and a second generating function relating to a second portion of the component.

Solution 19. the additive manufacturing system of solution 12, further comprising a user input interface, wherein the at least one generating function is executable to define the curve based on at least one user input.

Solution 20 the additive manufacturing system of claim 12, wherein the at least one generation function is encrypted and the controller is configured to read a key of the build file to decrypt the at least one generation function.

Drawings

These and other features, aspects, and advantages of the present application will become better understood when the following detailed description is read with reference to the accompanying drawings in which like characters represent like parts throughout the drawings, wherein:

fig. 1 is a schematic diagram of an exemplary additive manufacturing system;

FIG. 2 is a schematic view of set points for a consolidation apparatus of the additive manufacturing system shown in FIG. 1;

FIG. 3 is a flow diagram of an exemplary method of producing a component using the additive manufacturing system shown in FIG. 1;

FIG. 4 is a diagram of an exemplary curve generated using a function, a set of function parameters, and a set of seed values; and

FIG. 5 is a graphical representation of an exemplary curve generated using a function and different inputs.

The drawings provided in this specification are intended to illustrate features of embodiments of the present application, unless otherwise indicated. These features are believed to be applicable to a wide variety of systems including one or more embodiments of the present application. Thus, the drawings are not intended to include all of the conventional features known to those skilled in the art to be required to practice the embodiments disclosed in the present specification.

Detailed Description

In the following specification and claims, reference will be made to a number of terms, which shall be defined to have the following meanings.

The singular forms "a", "an" and "the" include plural referents unless the context clearly dictates otherwise.

"optional" or "optionally" means that the subsequently described event or circumstance may or may not occur, and that the description includes instances where the event occurs and instances where it does not.

Approximating language, as used herein throughout the specification and claims, may be applied to modify any quantitative representation that could permissibly vary without resulting in a change in the basic function to which it is related. Accordingly, a value modified by a term or terms, such as "about", "about" and "substantially", are not to be limited to the precise value specified. In at least some instances, the approximating language may correspond to the precision of an instrument for measuring the value. Here and throughout the present description and claims, range limitations may be combined and/or interchanged. Such ranges may be identified, and include all subranges included therein, unless context or language indicates otherwise.

As used in this specification, the terms "processor" and "computer" and related terms (e.g., "processing device," "computing device," and "controller") are not limited to just those integrated circuits referred to in the art as a computer, but broadly refer to a microcontroller, a microcomputer, a Programmable Logic Controller (PLC), and an application specific integrated circuit, as well as other programmable circuits, and these terms are used interchangeably herein. In the embodiments described in this specification, memory may include, but is not limited to, computer-readable media such as Random Access Memory (RAM) and computer-readable non-volatile media such as flash memory. Alternatively, a floppy disk, a compact disc read only memory (CD-ROM), a magneto-optical disk (MOD), and/or a Digital Versatile Disc (DVD) may also be used. Also, in the embodiments described in this specification, the additional input channels may be, but are not limited to, computer peripherals associated with operator interfaces such as a mouse and a keyboard. Alternatively, other computer peripherals may be used, which may include, for example, but are not limited to, a scanner. Further, in the exemplary embodiment, additional output channels may include, but are not limited to, an operator interface monitor.

Furthermore, as used in this specification, the terms "software" and "firmware" are interchangeable, and include any computer program stored in memory for execution by a personal computer, workstation, client and server.

As used in this specification, the term "non-transitory computer-readable medium" is intended to represent any tangible computer-based device implemented in any technology method for the short and long term storage of information such as computer-readable instructions, data structures, program modules and sub-modules, or other data in any device. Thus, the methods described in this specification may be encoded as executable instructions embodied within a tangible, non-transitory computer-readable medium, including but not limited to storage devices and/or memory devices. Such instructions, when executed by a processor, cause the processor to perform at least a portion of the methods described in this specification. Furthermore, as used in this specification, the term "non-transitory computer readable medium" includes all tangible computer readable media, including but not limited to non-transitory computer storage devices, including but not limited to volatile and non-volatile media, and removable and non-removable media, such as firmware, physical and virtual storage, CD-ROMs, DVDs, and any other digital source, such as a network or the Internet, as well as digital means yet to be developed, with the only exception being a transitory propagating signal.

Further, as used in this specification, the term "real-time" refers to at least one of the time of occurrence of an associated event, the time of measurement and collection of predetermined data, the time of processing data, and the time of system response to the event and environment. In the embodiments described in this specification, these activities and events occur substantially instantaneously.

The term "function" as used in this specification refers to an expression or equation that includes one or more variables.

Also, the term "build file" as used in this specification refers to an electronic representation of a component used in manufacturing the component.

Embodiments of the present application provide systems and methods for manufacturing components using an additive manufacturing process. The part is manufactured using a build file that includes the function. A curve is generated using the function, the at least one function parameter, and the at least one seed value. In some embodiments, the curve includes at least one non-linear portion. Thus, building the file reduces the time to transfer and process the data as compared to at least some known systems. Further, the build file allows the additive manufacturing system to manufacture the part with improved accuracy and less error because the controller directs the consolidation device along a curve generated using the function, the at least one function parameter, and the at least one seed value.

Fig. 1 is a schematic diagram of an exemplary additive manufacturing system 100. In an exemplary embodiment, additive manufacturing system 100 is a Direct Metal Laser Melting (DMLM) system. Although embodiments in this specification are described with reference to a DMLM system, the present application is also applicable to other types of additive manufacturing systems, for example, liquid-resin based additive manufacturing systems (e.g., stereolithography systems) or selective laser melting systems.

In an exemplary embodiment, additive manufacturing system 100 includes an additive manufacturing device 102. Additive manufacturing device 102 includes a build platform 104 to support a three-dimensional part 106 during an additive manufacturing process, a powder bed 108 including a particulate build material 110, and an energy source 112. The energy source 112 emits an energy beam 114 to sinter, cure, harden, or otherwise solidify or consolidate a portion of the powder bed 108 to form the three-dimensional part 106 from a plurality of stacked build layers 116. In fig. 1, various portions of the powder bed 108 are omitted for simplicity. Any three-dimensional part is manufactured using additive manufacturing system 100. In the exemplary embodiment, three-dimensional part 106 is an aircraft part.

Also, in the exemplary embodiment, energy source 112 is a laser device. For example, in some embodiments, the energy source 112 is a fiber laser device or a diode laser device. In alternative embodiments, additive manufacturing system 100 includes any energy source 112 that enables additive manufacturing system 100 to operate as described herein. For example, in some embodiments, additive manufacturing system 100 includes, but is not limited to, an ultraviolet laser, a gas laser (e.g., carbon dioxide (CO)₂) Laser), a light source, and an electron beam generator. In further embodiments, additive manufacturing system 100 includes two or more energy sources 112 having similar powers or different powers.

Also, in the exemplary embodiment, particulate build material 110 is a metal powder. More specifically, the particulate build material 110 is a gas atomized metal powder (e.g., cobalt, iron, aluminum, titanium, and/or nickel alloy) having an average particle size (particle size) in the range of about 10 and 100 microns. In alternative embodiments, powder bed 108 includes any particulate build material 110 that enables additive manufacturing system 100 to operate as described herein.

Additionally, in the exemplary embodiment, additive manufacturing system 100 includes a build material dispenser and dispensing device, which is also referred to as a coating or positioning device 124; an imaging device 126; and a consolidation apparatus 128. Coating device 124 is configured to provide a thin layer of particulate build material 110 on a surface, such as a surface of component 106, in operation of additive manufacturing device 102. An imaging device 126 is coupled to the coating device 124 and is configured to record and/or store visible wavelength data images of each build layer 116 and the resulting surface of the three-dimensional part 106.

Also, in the exemplary embodiment, additive manufacturing device 102 includes a consolidation device 128 that is used to consolidate portions of powder bed 108. Consolidation includes, for example, but not limited to, bonding, integrating, melting, binding, and/or unifying the particulate build material 110. In some embodiments, consolidation apparatus 128 includes, for example, but not limited to, an electromagnetic radiation source for bonding, integrating, melting, binding, and/or unifying particulate build material 110. In the exemplary embodiment, consolidation apparatus 128 includes one or more galvanometer optical scanners 130 and/or one or more motorized mirrors, lenses, and/or other optical devices. The consolidation device 128 is configured to scan the energy beam 114 over selective portions of the powder bed 108. In alternative embodiments, additive manufacturing system 100 includes any consolidation device 128 that enables additive manufacturing system 100 to operate as described herein.

In the exemplary embodiment, consolidation apparatus 128, energy source 112, imaging apparatus 126, and coating apparatus 124 are communicatively coupled to a controller 132. Also, in the exemplary embodiment, controller 132 is communicatively coupled to a computing device 134. In an alternative embodiment, controller 132 is communicatively coupled to any component that enables additive manufacturing system 100 to operate as described herein.

In operation, additive manufacturing system 100 manufactures three-dimensional part 106 through a layer-by-layer manufacturing process. More specifically, the three-dimensional part 106 is fabricated from a model that includes an electronic representation of the three-dimensional geometry of the three-dimensional part 106. The electronic representation is generated, for example, in a Computer Aided Design (CAD) file or similar electronic file. In alternative embodiments, the electronic representation is any electronic representation that enables additive manufacturing system 100 to operate as described herein.

In an exemplary embodiment, a build file (or files) is generated based on the electronic representation. In some embodiments, the build file includes at least one generating function, at least one function parameter, and at least one seed value. In operation, a curve representing the three-dimensional geometry is generated using the at least one generating function, the at least one function parameter, and the at least one seed value. The at least one seed value is provided separately from the at least one generating function and/or the at least one function parameter. For example, in some embodiments, at least one generating function is stored on the controller 132 and at least one seed value is provided to the controller 132. The at least one seed value is combined with at least one generating function on the controller 132 and, if necessary, at least one function parameter to complete the build file to generate a curve for the three-dimensional component 106. In a further embodiment, the at least one generating function and/or the at least one function parameter is provided with at least one seed value. In some embodiments, the curve includes at least one non-linear section. As a result, additive manufacturing system 100 is able to more accurately produce three-dimensional part 106 including complex shapes and curves than at least some known systems that have approximated curved portions of three-dimensional part 106 using vectors or linear segments. Additionally, additive manufacturing system 100 reduces manufacturing time because build file data is less dense than files used in at least some known systems.

In some embodiments, the build file includes a plurality of functions representing different portions of the three-dimensional part 106. For example, in some embodiments, the build file has a hierarchical format that includes at least one function for each build layer 116. For the layer-by-layer format, the geometry of the three-dimensional part 106 is sliced into a stack of two-dimensional build layers 116 of a desired thickness such that the geometry of each build layer 116 is the contour of a cross-section through the three-dimensional part 106 at that particular build layer 116 location. In an exemplary embodiment, one or more functions allow controller 132 to store and process build files for the entire three-dimensional part 106 at once. In addition, the build file causes controller 132 to compare different portions of three-dimensional part 106 during operation of additive manufacturing system 100. In alternative embodiments, additive manufacturing system 100 uses any build file that enables additive manufacturing system 100 to operate as described herein. For example, in some embodiments, the build file includes at least one function for generating at least one of, but not limited to, a B-spline curve, a Hilbert curve, a lattice (lattice), and a cell (unit cell).

In some embodiments, the build file includes an encryption key that allows one or more functions of the build file to be encrypted. When the build file is loaded on the controller 132 and/or the computing device 134, the controller 132 and/or the computing device 134 reads the encryption key and the build file is decrypted. In alternative embodiments, additive manufacturing system 100 uses any encryption system that enables additive manufacturing system 100 to operate as described herein.

In an exemplary embodiment, additive manufacturing system 100 does not use a pre-existing article as a precursor to the final part, rather the process creates three-dimensional part 106 from a feedstock in a configurable form, such as powdered particulate build material 110. For example, in some embodiments, the steel alloy material is additively manufactured using a steel alloy powder. In an alternative embodiment, additive manufacturing system 100 produces three-dimensional part 106 from any material that enables additive manufacturing system 100 to operate as described herein.

Additive manufacturing processes and systems include, for example, but are not limited to, photo polymerization curing (vat photopolymerization), powder bed fusion, binder jetting, material jetting, sheet lamination, material extrusion, directed energy deposition, and mixing systems. These methods and systems include, for example but not limited to SLA-stereolithography; DLP-digital light processing; 3 SP-scanning, spin and selective photocuring, CLIP-continuous liquid interface generation; SLS-selective laser sintering; DMLS-direct metal laser sintering; SLM-selective laser melting; EBM-electron beam melting; SHS-selective heat sintering; MJF-multiple nozzle fusion; 3D printing; jetting a voxel; polymer spraying; SCP-smooth curvature printing; MJM-multiple nozzle modeling project; LOM-layered object fabrication; SDL-selective deposition lamination; UAM-ultrasonic additive manufacturing; FFF-bonded filament manufacturing; FDM-fused deposition modeling; LMD-laser metal deposition; LENS-laser proximal fabrication; DMD-direct metal deposition; a mixing system; and combinations of these methods and systems. These methods and systems may use, for example, but not limited to, all forms of electromagnetic radiation, heating, sintering, melting, curing, bonding, consolidating, pressing, embedding, and combinations thereof.

Materials used in the additive manufacturing methods and systems include, for example, but are not limited to, polymers, plastics, metals, ceramics, sand, glass, waxes, fibers, biomass, composites, and mixtures of these materials. These materials may be used in the methods and systems in a variety of forms suitable for the particular material and method or system, including for example, but not limited to, liquids, solids, powders, plates, foils, tapes, filaments, pellets, liquids, slurries, wires, mists, pastes, and combinations of these forms.

The term "build parameter" as used in this specification refers to a characteristic used to define an operating condition of additive manufacturing system 100, such as a power output of energy source 112, a consolidation speed of energy source 112, a raster power output of energy source 112, a raster consolidation speed of energy source 112, a raster tool path of energy source 112, and a constant power (constant power) output of energy source 112 within additive manufacturing system 100. In some embodiments, the build parameters are initially input into computer device 134 by a user. The build parameter represents a given operating state of the additive manufacturing system 100.

The term "function parameter" as used in this specification refers to an input value to a constant of a function. In some embodiments, the set of function parameters is sent to the controller 132 separately from the generation function. In further embodiments, a set of function parameters is stored on the controller 132, at least one set of function parameters being selected for one or more curves. Thus, the function parameters allow the function to represent a plurality of different curves and reduce the data required to generate the curves.

The term "seed value" as used in this specification refers to an input value to a variable of a function. In an exemplary embodiment, the set of seed values is provided separately from the generating function and the function parameters. The seed value is determined based on the particular profile of the component. Because the build file includes functions and function parameters, the set of seed values required to generate the curve is reduced as compared to approximating the curve using a list of coordinate points or vectors in at least some known systems. In an alternative embodiment, the build file includes any value that enables additive manufacturing system 100 to operate as described in this specification.

During operation of additive manufacturing system 100, coating device 124 is positioned adjacent to build platform 104. The coating device 124 extends across the powder bed 108 in the transverse dimension and translates in the longitudinal dimension during recoating. As the coating device 124 moves in the longitudinal direction, the coating device 124 deposits and dispenses a layer of particulate build material 110 on the build platform 104, forming a build layer 116. After forming the build layer 116, the energy source 112 channels the energy beam 114 through the consolidation device 128 to direct the energy beam 114 over selected portions of the build layer 116 along a scan path. For example, the current meter 130 of the consolidation device 128 directs the energy beam 114 over selective portions of the build layer 116 to form new portions of the three-dimensional part 106. This process is then repeated for a plurality of build layers 116 to form the three-dimensional part 106. Along with the coating device 124 moving along the powder bed 108, the imaging device 126 is used to record and/or store visible wavelength data images of each build layer 116 and the resulting surface of the three-dimensional part 106. The generated image is then compared to an electronic computing mechanism build file to verify the manufacturing process.

In the exemplary embodiment, build platform 104, energy source 112, coating device 124, imaging device 126, and consolidation device 128 are operatively controlled by a controller 132. Controller 132 is any controller that enables additive manufacturing system 100 to operate as described herein. In the exemplary embodiment, controller 132 is operatively coupled to a computing device 134. In some embodiments, the controller 132 is a computer system that includes at least one processor and at least one memory device.

Also, in the exemplary embodiment, computing device 134 includes at least one memory device 144 and at least one processor 146 coupled to memory device 144. In some embodiments, processor 146 includes one or more processing units, such as, but not limited to, a multi-core configuration. In the exemplary embodiment, processor 146 includes a Field Programmable Gate Array (FPGA). In some embodiments, the executable instructions are stored in memory device 144. For example, in some embodiments, the processor 146 is programmed by encoding an operation as one or more executable instructions and providing the executable instructions in the memory device 144. In the exemplary embodiment, memory device 144 includes one or more devices that enable the storage and retrieval of information, such as executable instructions and/or other data. In some embodiments, memory device 144 includes one or more computer-readable media such as, but not limited to, Random Access Memory (RAM), dynamic RAM, static RAM, solid state disk, hard disk, Read Only Memory (ROM), erasable programmable ROM, electrically erasable programmable ROM, or non-volatile RAM memory. In alternative embodiments, additive manufacturing system 100 includes any computing device 134 that enables additive manufacturing system 100 to operate as described herein.

Further, in some embodiments, memory device 144 is configured to store data, such as build files used to direct consolidation device 128 and images generated by imaging device 126. In an alternative embodiment, memory device 144 stores any data that enables additive manufacturing system 100 to operate as described in this specification. In some embodiments, processor 146 removes or "sanitizes" data from memory device 144 based on the age of the data. For example, the processor 146 may overwrite previously recorded and stored data associated with a subsequent time or event. In further embodiments, the processor 146 removes data that exceeds a predetermined time interval. Additionally, memory device 144 includes, but is not limited to, sufficient data, algorithms, and commands to facilitate monitoring and measuring build parameters and geometries of three-dimensional part 106 manufactured by additive manufacturing system 100.

Moreover, in the exemplary embodiment, computing device 134 includes a presentation interface 148 that is coupled to processor 146. The presentation interface 148 presents information, such as images generated by the imaging device 126, to a user. In one embodiment, presentation interface 148 includes a display adapter (not shown) that connects to a display device (not shown), such as a Cathode Ray Tube (CRT), Liquid Crystal Display (LCD), Organic LED (OLED) display, or "electronic ink" display. In some embodiments, presentation interface 148 includes one or more display devices. In some embodiments, presentation interface 148 includes an audio output device (not shown), such as, but not limited to, an audio adapter or speaker (not shown).

Also, in the exemplary embodiment, computing device 134 includes a user input interface 150. In the exemplary embodiment, a user input interface 150 is coupled to processor 146 and receives input from a user. In some embodiments, the user input interface 150 includes, for example, but is not limited to, a keyboard; an indicating device; a mouse; a stylus pen; a touch sensitive panel such as, but not limited to, a touch pad or a touch screen; and/or an audio input interface such as, but not limited to, a microphone. In further embodiments, a single component, such as a touch screen, may serve as a display device for both the presentation interface 148 and the user input interface 150.

Additionally, in the exemplary embodiment, communication interface 152 is coupled to processor 146 and is configured to be communicatively coupled with one or more other devices, such as controller 132, and to perform input and output operations with respect to such devices while executing as input channels. For example, in some embodiments, communication interface 152 includes, but is not limited to, a wired network adapter, a wireless network adapter, a mobile telecommunications adapter, a serial communications adapter, or a parallel communications adapter. The communication interface 152 receives data signals from or transmits data signals to one or more remote devices.

Both the presentation interface 148 and the communication interface 152 can provide information suitable for use with the methods described herein, such as providing information to a user or the processor 146. Accordingly, presentation interface 148 and communication interface 152 may be referred to as output devices. Similarly, the user input interface 150 and the communication interface 152 are capable of receiving information suitable for use with the methods described in this specification, and are each referred to as an input device.

Fig. 2 is a schematic of a set point 154 for a consolidation apparatus 128 of additive manufacturing system 100 (shown in fig. 1). The set point 154 is located along a curve 156 generated using the function, the at least one function parameter, and the at least one seed value. The curve 156 includes a non-linear section 158. In the exemplary embodiment, non-linear section 158 is rounded and has a concave shape and a convex shape. In alternative embodiments, curve 156 has any shape that enables additive manufacturing system 100 (shown in fig. 1) to operate as described herein.

In some embodiments, curve 156 corresponds to an electronic model. Specifically, in some embodiments, the controller 132 converts the electronic model directly into the curve 156. As a result, the curve 156 allows the consolidation apparatus 128 (shown in FIG. 1) to accurately form the three-dimensional part 106 (shown in FIG. 1). In addition, curve 156 reduces delay, e.g., delay due to changes in the direction of nodes between linear segments of the approximation curve. In an alternative embodiment, setpoint 154 is positioned along any curve that enables additive manufacturing system 100 (shown in fig. 1) to operate as described in this specification.

In the exemplary embodiment, setpoints 154 are spaced apart a distance 160 such that setpoints 154 form a series of steps for consolidation apparatus 128. In some embodiments, the distance 160 is determined by the resolution of the consolidation apparatus 128 (shown in FIG. 1). The controller 132 causes the three-dimensional part 106 (shown in FIG. 1) to be produced at the maximum resolution of the consolidation apparatus 128 (shown in FIG. 1) because the set point 154 is positioned directly along the curve 156 rather than along a linear segment of an approximate curve. The maximum resolution is determined by a distance limit or a time limit on the controller 132. Thus, in some embodiments, the time between set points 154 is determined by the resolution of the consolidation apparatus 128 (shown in FIG. 1). In alternative embodiments, consolidation device 128 has any resolution that enables additive manufacturing system 100 (shown in fig. 1) to operate as described herein.

Fig. 3 is a flow diagram of an example method 200 of manufacturing a component 106 (shown in fig. 1) using the additive manufacturing system 100 (shown in fig. 1). Referring to fig. 1 and 2, a method 200 generally includes providing 202 a build file including functions, seed values, and function parameters. The 202 function is provided in any manner that enables the additive manufacturing system 100 to operate as described in this specification. For example, in some embodiments, providing 202 includes selecting one or more functions corresponding to portions of the model from functions stored in a database. In some embodiments, the database includes functions related to curves applicable to a plurality of three-dimensional components 106. Thus, in some embodiments, a function is generated for multiple components 106, with a function parameter and/or seed value provided for each component 106. In further embodiments, at least one function is customized for a particular three-dimensional part 106. In alternative embodiments, additive manufacturing system 100 uses any function that enables additive manufacturing system 100 to operate as described in this specification.

In some embodiments, the function is embodied in program code. The program code includes computer readable instructions that allow the controller to direct the consolidation apparatus. In some embodiments, program code associated with a particular component is written. In further embodiments, the program code is used for a plurality of components.

Also, in some embodiments, the build files and functions are sent to the controller 132 using signals. In further embodiments, at least a portion of the build file is generated and/or stored on the controller 132. In alternative embodiments, the build file is provided in any manner that enables additive manufacturing system 100 to operate as described herein.

Further, in the exemplary embodiment, method 200 includes generating 204 a curve that corresponds to the model of three-dimensional component 106. The curve is defined using at least one function, at least one seed value, and at least one function parameter.

Moreover, in the exemplary embodiment, method 200 includes depositing or positioning 206 material 110 on a surface. In some embodiments, material 110 is deposited onto successive build layers 116 in a layer-by-layer build process, and the superposed build layers 116 form three-dimensional part 106. In alternative embodiments, material 110 is deposited in any manner that enables additive manufacturing system 100 to operate as described herein.

Also, in some embodiments, the method 200 includes determining 208 a set point 154 (shown in FIG. 2) of the consolidation apparatus 128 along a curve defined by the function. In the exemplary embodiment, each setpoint 154 of consolidation apparatus 128 is directly on the curve. As a result, the additive manufacturing system 100 is able to utilize the full resolution of the consolidation apparatus 128 because the consolidation apparatus 128 is guided along a curve that directly corresponds to the model of the three-dimensional part 106. Additionally, the method 200 reduces error in generating the three-dimensional part 106 because the additive manufacturing system 100 does not require linear sections to approximate the curve. In some embodiments, the actual position of the consolidation apparatus 128 is compared to the set point 154.

Moreover, in the exemplary embodiment, method 200 includes an operation 210 of consolidation apparatus 128 to consolidate material 110 along a scan path. In particular, the controller 132 directs the consolidation apparatus 128 along a curve defined by a function of the build file. While the controller is directed along the curve, the consolidation apparatus 128 consolidates the material 110 along the scan path to form the build layer 116. In alternative embodiments, additive manufacturing system 100 consolidates material 110 in any manner that enables additive manufacturing system 100 to operate as described herein.

FIG. 4 is an illustration of an exemplary curve 300 generated using a function, a set of function parameters, and a set of seed values. In the exemplary embodiment, curve 300 is a B-spline curve and includes a non-linear portion 302. In an alternative embodiment, additive manufacturing system 100 (shown in fig. 1) generates any curve 300 that enables additive manufacturing system 100 to operate as described in this specification.

In some embodiments, the function is included in program code such as:

//Marking a B-Spline Curve

jump_abs(x0,y0)；

bspline_abs(5,x1,y1,x2,y2,x3,y3,x4,y4,x5,y5)；

where x and y are variables.

in the exemplary embodiment, curve 300 is generated by at least one input value for an x variable and a y variable. Thus, the curve 300 needs to generate less data than a similar curve defined by a list of coordinates and/or vectors. As a result, the build file including this function causes a complex curve to be generated from an electronic file having a smaller size than an electronic file including a comprehensive list of coordinate data.

FIG. 5 is a graphical representation of

exemplary curves

400, 402 generated using functions and different inputs. In the exemplary embodiment, curves 400 and 402 are hilbert curves. In an alternative embodiment, the function defines any of the

curves

400, 402 that enable the additive manufacturing system 100 (shown in fig. 1) to operate as described in this specification.

In some embodiments, the function is included in program code such as:

wherein x0, y0, xi, yi, yj, Z and n are variables. In an exemplary embodiment, the program code is a recursive function. The function allows different curves to be generated by inputting different variables. For example, by changing the input variables, the dimensions and spacing of the

curves

400, 402 are changed.

In operation, a call is entered to cause program code to run and generate the

curves

400, 402. Example calls to program code include:

Hilbert(startX,startY,1.0,0.0,0.0,1.0,0.01,nDimensions,sizeMode1X,sizeMode1Y)

where startX, startY,1.0,0.0,0.0,1.0,0.01, nDimensions, sizeMode1X and sizeMode1Y are input variables.

In an exemplary embodiment, curve 400 and curve 402 are generated by inputting different values into the function for the nDimensions variable input. In some embodiments, either variable is changed to generate a curve different from curve 400 and curve 402. Thus, the function allows simpler changes to the build file because the curve is customized by changing one or more values of the function rather than changing a series of coordinate data. In an alternative embodiment, the variables are provided with any values that cause additive manufacturing system 100 (shown in fig. 1) to operate as described in this specification. For example, in some embodiments, the functions and function parameters provide unit cells. In further embodiments, at least one variable of the function is varied to provide a curve that includes a desired number of unit cell units. The term "unit cell" as used in this specification refers to a repeating unit of repeating pattern.

The embodiments described above provide systems and methods for manufacturing components using additive manufacturing processes. The part is manufactured using a build file that includes the function. A curve is generated using the function, the at least one function parameter, and the at least one seed value. In some embodiments, the curve includes at least one non-linear portion. Thus, building the file reduces the time to transfer and process the data as compared to at least some known systems. Further, the build file allows the additive manufacturing system to manufacture the part with improved accuracy and less error because the controller directs the consolidation device along a curve generated using the function, the at least one function parameter, and the at least one seed value.

Exemplary technical effects of the systems and methods described in this specification include at least one of: (a) reducing processing and/or transfer time of electronic files used in generating three-dimensional parts; (b) reducing the cost of assembling a three-dimensional part using an additive manufacturing system; (c) improving the precision of producing three-dimensional parts; and (d) improving compatibility of the additive manufacturing system with the modeling software.

Exemplary embodiments of systems and methods for additive manufacturing are described above in detail. The methods and systems are not limited to the specific embodiments described herein, but rather, components of systems and/or steps of the methods may be utilized independently and separately from other components or steps described herein. For example, the methods may also be used in combination with other systems, and are not limited to practice with only additive manufacturing systems as described in this specification. Rather, the exemplary embodiment can be implemented and utilized in connection with many other applications.

Although specific features of various embodiments of the invention may be shown in some drawings and not in others, this is for convenience only. In accordance with the principles of embodiments of the present application, any feature of a drawing may be referenced and/or claimed in combination with any feature of any other drawing.

Some embodiments include the use of one or more electronic or computing devices. Such devices typically include a processor, processing device, or controller, such as a general purpose Central Processing Unit (CPU), a Graphics Processing Unit (GPU), a microcontroller, a Reduced Instruction Set Computer (RISC) processor, an Application Specific Integrated Circuit (ASIC), a Programmable Logic Circuit (PLC), a Field Programmable Gate Array (FPGA), a Digital Signal Processing (DSP) device, and/or any other circuit or processing device capable of performing the functions described in this specification. The methods described in this specification may be encoded as executable instructions embodied in a computer-readable medium, which includes, without limitation, a storage device and/or a memory device. Such instructions, when executed by a processing device, cause the processing device to perform at least a portion of the methods described in this specification. The above embodiments are exemplary only, and are thus not intended to limit in any way the definition and/or meaning of the terms processor and processing device.

This written description uses examples to disclose embodiments of the application, including the best mode, and also to enable any person skilled in the art to practice embodiments of the application, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the embodiments described in this specification is defined by the claims, and may include other embodiments that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims.

Claims

1. A method of manufacturing a component using an additive manufacturing system, the method comprising:

providing a build file on a controller of an additive manufacturing system, wherein the build file comprises at least one generation function, at least one seed value, and at least one function parameter;

generating a curve corresponding to the component based on the at least one generating function, the at least one seed value, and the at least one function parameter;

positioning a material on a surface;

determining, using the controller, a plurality of set points for a consolidation device of the additive manufacturing system, wherein the plurality of set points are positioned along the curve to form a series of equidistant steps for the consolidation device, and wherein the plurality of set points are spaced apart by a distance determined based on a resolution of the consolidation device; and

operating the consolidation apparatus to consolidate the material.

2. The method of claim 1, wherein the plurality of set points determined by the controller are located along a non-linear portion of the curve.

3. The method of claim 1, wherein providing a build file on a controller of the additive manufacturing system comprises providing program code comprising the at least one generating function, wherein at least a portion of the program code is customized for the part.

4. The method of claim 1, further comprising selecting the at least one generating function from a database.

5. The method of claim 1, wherein the at least one generating function defines at least one of a B-spline curve, a hilbert curve, a lattice, and a unit cell unit.

6. The method of claim 1, further comprising determining an actual position of the consolidation apparatus and comparing the actual position to the plurality of set points.

7. The method of claim 1, further comprising transmitting a build file for the component to the controller.

8. The method of claim 1, wherein the at least one generating function comprises a first generating function related to a first portion of the component and a second generating function related to a second portion of the component.

9. The method of claim 8, wherein the first layer of the component is formed using the first generating function and the second layer of the component is formed using the second generating function.

10. The method of claim 1, further comprising providing at least one user input to the at least one generating function, wherein the generating function is executable to define the curve based on the at least one user input.

11. The method of claim 1, wherein the at least one generation function is encrypted, the method further comprising reading a key of the build file to decrypt the generation function.

12. An additive manufacturing system for manufacturing a component using a build file, the additive manufacturing system comprising:

a controller configured to receive a build file, wherein the build file comprises at least one generation function, at least one seed value, and at least one function parameter;

a positioning device configured to position a material on a surface; and

a consolidation device connected to the controller and positionable relative to the surface, wherein the consolidation device is configured to consolidate material, wherein the controller is configured to determine a plurality of set points for the consolidation device along a curve defined by the at least one generating function, the at least one seed value, and the at least one function parameter, wherein the plurality of set points are positioned along the curve to form a series of equidistant steps for the consolidation device, and wherein the plurality of set points are spaced apart by a distance determined based on a resolution of the consolidation device.

13. The additive manufacturing system of claim 12, wherein a plurality of set points determined by the controller are located along a non-linear portion of the curve.

14. The additive manufacturing system of claim 12, wherein the build file comprises program code comprising the at least one generating function, wherein at least a portion of the program code is customized for the part.

15. The additive manufacturing system of claim 12, further comprising a database comprising a plurality of generating functions, wherein at least one generating function of the build file is selected from the generating functions in the database.

16. The additive manufacturing system of claim 12, wherein the at least one generating function defines at least one of a B-spline curve, a hilbert curve, a lattice, and a unit cell unit.

17. The additive manufacturing system of claim 12, further comprising an imaging device configured to provide an image for determining a true position of the consolidation device, wherein the controller is configured to compare the true position to the plurality of set points.

18. The additive manufacturing system of claim 12, wherein the at least one generating function comprises a first generating function related to a first portion of a component and a second generating function related to a second portion of the component.

19. The additive manufacturing system of claim 12, further comprising a user input interface, wherein the at least one generating function is executable to define the curve based on at least one user input.

20. The additive manufacturing system of claim 12, wherein the at least one generation function is encrypted and the controller is configured to read a key of the build file to decrypt the at least one generation function.